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Could be a multitude of things. Use only good quality thread--no old or bargain bin threads. Try a different brand of thread--some machines prefer certain brands over others. The needle and thread should be compatible--ie needle eye shouldn't be too small for thread weight. Burr catching the thread and breaking it. Upper tension too tight.
Remove the upper thread, RAISE the presser foot and rethread from the beginning. Verify the thread is not looped incorrectly in the thread path, like around a thread guide or around the spool pin. Is the thread snagging on the thread spool itself? Do you see the thread tightening as you sew and eventually it breaks? This indicates it is catching somewhere between the needle and spool. Is it shredding at the needle eye? This indicates the needle eye is not suitable for the thread being used.
Watch where the thread is breaking. This will sometimes give you a clue where the problem exists.
Breaking thread? Presumably the top thread? AVOID old or bargain bin threads. The upper tension is too tight or the thread is not properly seated in the tension disk, the needle is defective or the needle, needle eye/scarf is not the best choice for the fabric/thread being used, there may be a snag in the bobbin area that is catching the thread. Make sure the thread is not catching on the spool's thread notch.
There are several common reasons for upper thread breakage.
Check that the needle/thread/fabric are compatible. All About Needles
Remove the upper thread from the machine, install a brand new needle, ALWAYS RAISE the presser foot, and rethread from the beginning. Verify the thread path is correct. Set the upper tension to the midway point.
Install a brand new needle--one that matches the type of thread and fabric you are sewing. If the thread is shredding at the needle, then the needle's eye may be too small for the thread.
Avoid using old or bargain bin thread. Try a different type of thread.
Check that the thread is threaded correctly in the machine and that it is not wrapped around the thread spool or a thread guide. Also, set the upper tension to the midway point, ie the tension could be too tight.
When threading the upper thread, be sure to ALWAYS RAISE the presser foot so the thread will seat properly in the tension disks. Avoid old thread or bargain bin thread. If the thread is fraying and breaking at or near the needle eye, then try a different type of needle with a larger thread groove that will protect the thread from fraying on rough fabric. Also, check that the thread is not hanging up on something, ie the slit on the side of the spool where the thread tail is stored.
Usually thread breakage is a result of incorrect threading or the thread tension set too tight.
Install a brand new needle.
Remove the upper thread. RAISE the presser foot and rethread from the beginning (verify the threading sequence is correct).
Check that the tension is set at the midway point between the high and low numbers.
Retest. If still breaking, there are other less common problems (thread/needle incompatibility, burrs or knicks catching the thread, etc) that may be the cause. Check the following web sites:
I had the same problem with the blue thread- it would sew and inch then pop- mine worked wihtout breaking after I re threaded in this order: green, blue, red then yellow
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